End effector, system and method for picking up and placing an object

Abstract

Described herein is an end effector for picking up and placing an object on a rigid tool. The end effector comprises a plate and an internal seal attached to the plate. The internal seal comprises an internal permeable layer and an internal impermeable film. The end effector further comprises at least one vacuum port extending through the plate and open to the internal permeable layer. Additionally, the end effector may comprise an external seal attached to the plate. The external seal comprises an external permeable layer and an external impermeable film.

What is claimed is: 
     
       1. An end effector comprising:
 a plate comprising a first side and a second side, the second side being opposite the first side and configured to interface with an object; 
 an internal seal attached directly to the second side of the plate, the internal seal comprising:
 an internal permeable layer; and 
 an internal impermeable film about and extending beyond an entire periphery of the internal permeable layer and wrapping underneath a portion of the internal permeable layer such that, in a direction parallel to a thickness of the internal permeable layer, the entire periphery of the internal permeable layer is interposed between the second side of the plate and the internal impermeable film; and 
 
 at least one vacuum port extending through the plate and open to the internal permeable layer. 
 
     
     
       2. The end effector of  claim 1 , further comprising:
 an external seal attached to the first side of the plate, the external seal comprising:
 an external permeable layer extending from the first side of the plate beyond an outer periphery of the plate; and 
 an external impermeable film covering the external permeable layer such that the external permeable layer is interposed between the first side of the plate and the external impermeable film, the external impermeable film extending beyond an entire periphery of the external permeable layer and extending from the first side of the plate beyond the outer periphery of the plate. 
 
 
     
     
       3. The end effector of  claim 2 , wherein the internal permeable layer and the external permeable layer each comprises an open-celled material. 
     
     
       4. The end effector of  claim 3 , wherein the open-celled material comprises a bi-planar mesh. 
     
     
       5. The end effector of  claim 1 , wherein the internal seal is noncontiguous with the second side of the plate. 
     
     
       6. The end effector of  claim 1 , wherein the at least one vacuum port comprises slots arranged in a grid pattern. 
     
     
       7. The end effector of  claim 1 , wherein the plate is rigid. 
     
     
       8. The end effector of  claim 1 , wherein the plate is flexible. 
     
     
       9. The end effector of  claim 1 , wherein the internal impermeable film overlaps the internal permeable layer between 1 inch and 4 inches. 
     
     
       10. An end effector comprising:
 a plate comprising a first side and a second side, the second side being opposite the first side and configured to interface with an object; 
 an internal permeable layer attached to the second side of the plate; 
 an external seal attached to the first side of the plate; the external seal comprising:
 an external permeable layer extending from the first side of the plate beyond an outer periphery of the plate; and 
 an external impermeable film covering the external permeable layer such that the external permeable layer is interposed between the first side of the plate and the external impermeable film, the external impermeable film extending beyond an entire periphery of the external permeable layer and extending from the first side of the plate beyond the outer periphery of the plate; and 
 
 at least one vacuum port extending through the plate and open to the internal permeable layer. 
 
     
     
       11. The end effector of  claim 10 , wherein the internal permeable layer has a surface area equal to a surface area of the second side of the plate. 
     
     
       12. The end effector of  claim 10 , wherein the internal permeable layer has a surface area greater than a surface area of the second side of the plate. 
     
     
       13. The end effector of  claim 12 , further comprises:
 an internal impermeable film about and extending beyond an entire periphery of the internal permeable layer such that the entire periphery of the internal permeable layer is interposed between the second side of the plate and the internal impermeable film. 
 
     
     
       14. A method for picking up and placing an object, the method comprising:
 placing at least one end effector over an object, the at least one end effector comprising an external seal extending beyond an outer periphery of the at least one end effector, the external seal comprising an external permeable layer and an external impermeable film covering the external permeable layer and extending beyond an entire periphery of the external permeable layer; 
 connecting a high-flow vacuum to a vacuum port in the at least one end effector; 
 applying a negative pressure via the high-flow vacuum to seal the object to the at least one end effector at the external seal; 
 transporting the object while the negative pressure is retained; 
 locating the object on a rigid tool; 
 halting the negative pressure when the object is on the rigid tool; and 
 removing the at least one end effector from the object. 
 
     
     
       15. The method of  claim 14 , wherein placing the at least one end effector over the object comprises placing at least one end effector comprising an internal seal over the object, the internal seal interfacing with the object and comprising an internal permeable layer and an internal impermeable film about and extending beyond an entire periphery of the internal permeable layer; and
 applying the negative pressure comprises applying a negative pressure to seal the object to the at least one end effector at the internal seal and the external seal. 
 
     
     
       16. The method of  claim 14 , wherein:
 placing the at least one end effector over the object comprises placing multiple end effectors over an object; 
 connecting the high-flow vacuum comprises connecting the high-flow vacuum to a vacuum port in each end effector; 
 applying the negative pressure via the high-flow vacuum comprises synchronously applying the negative pressure via the high-flow vacuum to seal the object to the multiple end effectors at the external seal in each end effector; and 
 transporting the object comprising transporting the object by synchronously operating the multiple end effectors to transport the object. 
 
     
     
       17. The method of  claim 14 , further comprising shaping the object when the object is held under the negative pressure by the end effector by altering a shape of the end effector. 
     
     
       18. The method of  claim 14 , further comprising:
 shaping the object between the rigid tool and the end effector, while the object is held under negative pressure by the end effector, by altering the shape of the end effector. 
 
     
     
       19. The method of  claim 14 , wherein:
 the object comprises an uncured fiber reinforced laminate; and 
 placing the at least one end effector over the object comprises placing the at least one end effector over the uncured fiber reinforced laminate. 
 
     
     
       20. The method of  claim 14 , wherein:
 the object comprises a permeable object and an impermeable material underneath the entirety of the permeable object and extending beyond the periphery of the permeable object; and 
 placing the at least one end effector over the object comprises placing the at least one end effector over the permeable object and the impermeable material such that the permeable object is entirely interposed between the end effector and the impermeable material.